US9651184B2 - Wireless modules with power control circuits for heat trace system - Google Patents

Wireless modules with power control circuits for heat trace system Download PDF

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Publication number
US9651184B2
US9651184B2 US14/626,160 US201514626160A US9651184B2 US 9651184 B2 US9651184 B2 US 9651184B2 US 201514626160 A US201514626160 A US 201514626160A US 9651184 B2 US9651184 B2 US 9651184B2
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heat trace
sensor
wireless
power distribution
main power
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US14/626,160
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US20160245447A1 (en
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Mark Crombie
Adam Heiligenstein
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Chromalox Inc
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Chromalox Inc
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Assigned to CHROMALOX, INC. reassignment CHROMALOX, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CROMBIE, Mark, HEILIGENSTEIN, Adam
Priority to US14/626,160 priority Critical patent/US9651184B2/en
Priority to PCT/US2016/014152 priority patent/WO2016133641A1/en
Priority to ES16706275.1T priority patent/ES2686368T3/es
Priority to CA2976904A priority patent/CA2976904C/en
Priority to EP16706275.1A priority patent/EP3254531B1/en
Priority to CN201680018364.XA priority patent/CN107407452B/zh
Publication of US20160245447A1 publication Critical patent/US20160245447A1/en
Publication of US9651184B2 publication Critical patent/US9651184B2/en
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    • F16L53/008—
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L53/00—Heating of pipes or pipe systems; Cooling of pipes or pipe systems
    • F16L53/30—Heating of pipes or pipe systems
    • F16L53/35—Ohmic-resistance heating
    • F16L53/38—Ohmic-resistance heating using elongate electric heating elements, e.g. wires or ribbons
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04W—WIRELESS COMMUNICATION NETWORKS
    • H04W84/00—Network topologies
    • H04W84/18—Self-organising networks, e.g. ad-hoc networks or sensor networks
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B1/00—Details of electric heating devices
    • H05B1/02—Automatic switching arrangements specially adapted to apparatus ; Control of heating devices
    • H05B1/0227—Applications
    • H05B1/023—Industrial applications
    • H05B1/0244—Heating of fluids
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B1/00—Details of electric heating devices
    • H05B1/02—Automatic switching arrangements specially adapted to apparatus ; Control of heating devices
    • H05B1/0227—Applications
    • H05B1/0288—Applications for non specified applications
    • H05B1/0291—Tubular elements

Definitions

  • Heat trace systems are commonly used in industrial and commercial settings to maintain or raise the temperature of pipes or tanks in a piping system through the use of electrical heating elements or heat traces that are in physical contact with the pipe or tank, as the case may be.
  • the various heat traces are connected to, and receive electric power from, a main power distribution system.
  • the main power distribution system typically has a user interface that allows the user to configure the parameters of the heat trace system, such as the set point temperatures, the deadbands (a range over which the temperature is allowed to fluctuate), and high/low temperature alarms.
  • the main power distribution system typically includes a solid state relay (SSR) connected to each heat trace loop, and regulation of the SSR regulates the voltage applied to the heat trace loops (which thereby controls the temperatures of the pipes and tanks).
  • SSR solid state relay
  • Some heat trace systems also include wireless sensors or other wireless modules throughout the heat trace system.
  • the sensors can sense conditions of the heat traces and/or the pipes/tanks and report the sensed conditions to the main power distribution system via a wireless communication network.
  • these wireless modules are powered by either batteries or separate power cables.
  • the present invention is directed to a heat trace system for heating (or maintain the temperature of) vessels of a piping system, where the power control devices for the heat trace cables at the main power distribution and control system are eliminated, and instead replaced with power control devices at wireless modules (e.g., wireless sensor modules) that are distributed throughout the heat trace system.
  • the heat trace cables are connected to the power control devices in respective wireless modules such that when the power control device in a wireless module is on (conductive), the heat trace cable connected to that wireless module conducts current, and thereby heats the vessel contacting the heat trace cable.
  • the wireless module can receive control commands for controlling its power control device wirelessly from the main power distribution and control system via a wireless communication network.
  • one or more of the wireless modules can include a sensor (e.g., a temperature sensor, a flow sensor, a pH sensor, a level sensor, etc.).
  • the wireless module can report back the conditions sensed by the sensor to the main power distribution and control system via the wireless network.
  • the main power distribution and control system can use that information (e.g., sensed temperatures) in its control loops to control the switching of the power control devices in the wireless modules, to thereby control whether the associated heat trace cable conducts current or not, to thereby control the temperature at the vessel that is heated by the heat trace cable.
  • FIGS. 1 and 2 are diagram of a heat trace system according to various embodiments of the present invention.
  • FIG. 3 depicts aspects of a heat trace cable.
  • aspects of the present invention are directed generally to a heat trace system 10 where the power control devices (e.g., SSRs) for the heat trace cables 16 at the main power distribution and control system 12 are eliminated and replaced with power control devices 40 at the wireless modules (e.g., wireless sensor modules) 14 throughout the heat trace system 10 .
  • Each heat trace cable 16 is connected to the power control device 40 in its associated wireless module 14 such that when the power control device 40 in the wireless module 14 is on (conductive), the heat trace cable 16 connected to it conducts current, and thereby heats the pipe section 18 or tank 20 contacting the heat trace cable 16 .
  • the wireless module 14 can receive control commands for controlling its power control device 40 wirelessly from the main power distribution and control system 12 via a wireless data network 50 .
  • the wireless module 14 includes a sensor (e.g., a temperature sensor, a flow sensor, a pH sensor, a level sensor, etc.)
  • the wireless module 14 can report back the sensed conditions to the main power distribution and control system 12 via the wireless network 50 , and the main power distribution and control system 12 can use that information as necessary in its control loops to control the current to the heat trace cables 16 (e.g., control whether the power control devices 40 in the wireless modules 14 are conductive or not (on or off)).
  • the heat trace system 10 illustrated in FIGS. 1 and 2 includes a main power distribution and control center 12 , a number of wireless modules 14 (also referred to herein as “wireless field devices”), and a number of heat trace cables 16 .
  • Each heat trace cable 16 is adjacent to and contacts an associated fluid (gas or liquid)-carrying vessel, e.g., a pipe section 18 or a tank 20 , of the piping system to heat the pipe section 18 or tank 20 , as the case may be.
  • FIG. 1 shows two pipe sections 18 and one tank 20 that are each heated with a separate, respective heat trace cable 16 , which are shown schematically in FIG. 1 as resistors.
  • the piping system where a heat trace system according to the present invention is employed is likely to have multiple pipe sections and/or tanks to be heated, and each may have one or more associated heat trace cables that are powered as described herein.
  • the main power distribution and control center 12 comprises a controller 22 , a wireless gateway 24 , and an electrical power source 26 .
  • the controller 22 may be implemented as a smart, microprocessor-based, computer device (or a network of such devices) that, through programming, controls the operation of the heating system, including controlling the current applied to the heat trace cables 16 (to thereby control the heating therefrom).
  • the controller 18 may comprise at least one microprocessor 28 and at least one semiconductor memory unit 30 .
  • the memory unit 30 stores instructions, e.g., software or firmware, that is executed by the processor 28 .
  • the controller 22 determines when to turn on and off the power control devices 40 in the wireless modules 14 that control the current supplied to the various heat trace cables 16 .
  • the controller 22 can include a PID controller that controls the on/off cycles of the power control devices 40 of the wireless modules 14 based on, among other things, temperatures at the pipe sections 18 sensed by the wireless modules 14 and reported back to the main power distribution and control system 12 via the wireless network 50 to keep the temperature of the pipe sections 18 at desired (set) levels.
  • the control instructions are transmitted from the controller 22 of the main power distribution and control center 12 via the wireless network 50 to the appropriate wireless module 14 by the wireless gateway 24 of the main power distribution and control center 12 .
  • the wireless network 50 may be, for example, a self-organizing, self-healing wireless mesh communication network.
  • the wireless mesh communication network could be based on the IEEE 802.11 standards, the IEEE 802.15.4 standards, or the ISA-100.11a standard, for example.
  • the wireless gateway 24 may be a circuit, implemented in hardware and/or software, that provides a wireless connection for the main power distribution and control center 12 to the wireless network 50 .
  • the wireless gateway 24 may be, for example, a WirelessHART Gateway from Pepper1+Fuchs.
  • Each wireless module 14 can have a unique address on the network 50 that the wireless gateway 24 uses when sending communications via the network 50 to the individual wireless modules 14 .
  • the wireless gateway has a unique address that the wireless modules 14 use when communicating with the wireless gateway 24 via the network 50 .
  • the power source 26 may include AC mains power, e.g., 100-480 VAC single or three phase, with the AC current from the power source 26 carried to the wireless modules 14 via conductive wires 52 .
  • the alternating current from the power source 26 that is supplied to the heat trace cables 16 is not rectified such that the heat trace cables 16 conduct alternating current (e.g., 100-480V).
  • the voltage regulators 48 of the wireless modules 14 may convert the AC current from the power source 26 to appropriate low, control DC voltage(s) for powering components of the wireless module 14 .
  • the main power distribution and control center 12 may also include other features and components that are not shown in FIGS. 1 and 2 for the sake of clarity, such as a touch-screen user interface (or other human-machine interface (HMI)) that allows a user to program the desired heat levels for each heat trace cable 16 being controlled by the main power distribution and control center 12 , a ground fault circuit interrupter (GFI), a panel board, etc.
  • a touch-screen user interface or other human-machine interface (HMI)
  • HMI human-machine interface
  • GFI ground fault circuit interrupter
  • the power control devices 40 of the wireless modules 14 may be any suitable power control device that switches on or off when an external voltage is applied to its control (or gate) terminals, such as a solid state relay (SSR), triac, silicon controlled rectifier (SCR), contactor, etc.
  • the power control device has an input terminal connected via a wire 52 to the electrical power source 26 of the main power distribution and control center 12 , and its output is connected to one of the heat trace cables 16 .
  • Its gate or control terminal is connected to a controller 42 of the wireless module 14 , such that the power control device 40 is controlled (e.g., turned on and off) by the controller 42 (referred to in the claims as a “field device controller” to distinguish it in the claims from the controller 22 of the main power distribution and control center 12 ).
  • the heat trace cable 16 connected to the output of the power control device 40 of the wireless module 14 is connected to and receives electric power from the electric power source 26 in the main power distribution and control center 12 .
  • the heat trace cables 16 may each include two buss wires 60 A, 60 B surrounded by a conductive matrix 62 (which is preferable polymeric).
  • the conductive matrix 62 in turn may be surrounded a jacket 64 , which may be surrounded by a metallic (e.g., tinned copper) braid 66 and an overcoat over braid 68 (preferably Teflon).
  • the buss wires 60 A, 60 B carry electrical current from the power source 26 of the main power distribution and control system 12 when the power control device 40 in the wireless module 12 to which the heat trace cable 40 is connected to is on (e.g., conductive).
  • Heat from a heat trace cable 16 heats (or maintains the temperature of) the pipe section 18 or tank 20 that it contacts to offset any losses in the pipe or tank temperature. More details about the heat trace cables can be found in U.S. provisional patent application Ser. No. 61/865,851, filed Aug. 14, 2013, which is incorporated herein by reference in its entirety.
  • the controller 42 may be implemented as a microcontroller or other suitable electronic circuit or device that is programmed to control the power control device 40 and perform the other functions ascribed to the controller 42 that are described herein.
  • the control signal from the controller 42 may be coupled to the power control device 40 in a manner that provides galvanic isolation.
  • the power control device 40 may be a SSR that uses optical coupling.
  • the control circuit may include an internal LED that illuminates (when on) and switches on a corresponding photo-sensitive diode at the gate terminal of the power control device 40 to turn the power control device 40 on (make it conduct current from its input (the electrical power source 26 ) to its output (the heat trace cable 16 )).
  • the wireless modules 14 may include a voltage regulator 48 , an RF module 44 , and a sensor 46 .
  • the voltage regulator 48 can convert the voltage from the power source 26 on the wire 52 to a suitable voltage (e.g., 3.3V) for powering the controller 42 .
  • the voltage regulator 48 (or another voltage regulator) can also produce supply voltages for the RF module 44 and sensor 46 if necessary.
  • the RF module 44 is an electronic circuit or device that is in communication with the controller 42 and used to transmit and receive wireless communications via the wireless network 50 , using the communication protocol of the network 50 (e.g., IEEE 802.11 or WirelessHART), so that the wireless module 14 can communicate wirelessly with the main power distribution and control system 12 .
  • the sensor 46 can sense some external characteristic or quality of the heat trace or piping system.
  • the sensor 46 is in communication with the controller 42 .
  • the controller 42 may received the sensed parameters from the sensor 46 and report them to the main power distribution and control system 12 via the RF module 44 (and wireless network 50 ).
  • the sensor 46 in one or more of the wireless modules 14 could be a temperature sensor, such as a RTD, that senses the temperature at the associated pipe section 18 or tank 20 of the piping system that is heated by the heat trace cable 16 connected to the wireless module.
  • the controller 22 of the main power distribution and control system 12 can use the sensed temperatures at the pipe section or tank (reported to it wirelessly by the wireless module 14 ) in a control loop to control the power control device 40 at the wireless module 14 , to thereby control the current to the connected heat trace cable 16 , to thereby control the temperature at the pipe section 18 or tank 20 heated by the heat trace cable 16 .
  • wireless modules 14 in the heat trace system 10 could have other types of sensors.
  • the sensor 46 could be a flowmeter, a vibration sensor, a pH monitor, a tank level sensor, a valve position sensor, etc.
  • a flowmeter senses the fluid flow in a pipe section and could comprise a differential pressure flowmeter, a magnetic flowmeter, a vortex flowmeter, or any other suitable type of flowmeter.
  • a wireless module 14 having such a flowmeter may periodically transmit wirelessly the measured fluid flow for its associated pipe section 18 to the main power distribution and control system 12 .
  • a vibration sensor can sense vibration of an associated pipe section 18 .
  • the vibration sensor 212 may comprise, for example, one or more accelerometers for detecting movement due to vibrations in one or more directions (or degrees of freedom).
  • a wireless module 14 having such a vibration sensor may periodically transmit wirelessly the measured vibration levels for its pipe section 18 to the main power distribution and control system 12 .
  • a pH monitor can sense the pH level of the fluid in the tank 20 and a wireless module 14 having such a pH monitor can periodically transmit wirelessly the measured pH levels to the main power distribution and control system 12 .
  • a level sensor can sense the level of the fluid in the tank 20 and a wireless module 14 having such a level sensor can periodically transmit wirelessly the measured fluid levels in the tank 20 to the main power distribution and control system 12 .
  • the level sensor can comprise, for example, a tank fluid measurement device and/or a level switch. Tank level measurement devices can use non-contact level measuring technologies such as radar to detect the level of the fluid in the tank.
  • Tank level switches are triggered when the fluid in the tank reaches a pre-established level.
  • a valve position sensor can detect the position of a valve (not shown) in the piping system and a wireless module 14 having such a valve sensor can periodically transmit wirelessly the valve position status to the main power distribution and control system 16 .
  • the present invention is directed to a heat trace system 10 for heating vessels 18 , 20 of a piping system.
  • the heat trace system 10 comprises a main power distribution and control unit 12 , a plurality of heat trace cables 16 , and a plurality of wireless field devices 14 .
  • the main power distribution and control unit 12 comprises an electrical power source 26 , a wireless communication gateway 24 , and a front-end controller 22 in communication with wireless communication gateway 24 .
  • Each heat trace cable 16 is adjacent to a vessel 18 , 20 of the piping system to heat, or to maintain the temperature of, the vessel.
  • Each wireless field devices comprises a power control device 40 , an RF module 44 , and a field device controller 42 .
  • the power control device comprises an input connected to the electrical power source 26 of the main power distribution and control unit 12 , and comprises an output connected to an associated heat trace cable 16 , such that when the power control device 40 is ON, the associated heat trace cable 16 conducts current from the electrical power source 26 of the main power distribution and control unit 12 .
  • the RF module 44 communicates with the wireless communication gateway 24 of the main power distribution and control unit 12 via a wireless communication network 50 .
  • the field device controller 42 controls the power control device 40 based on control data sent from the front end controller 22 of the main power distribution and control unit 12 via the wireless communication network 50 to the wireless field device 14 and received by the RF module 44 .
  • At least one of the wireless field devices further comprises a sensor.
  • the field device controller of that wireless field device is in communication with the sensor and transmits sensed data from the sensor via the RF module and the wireless communication network to the front-end controller of the main power distribution and control unit.
  • the sensor could be a temperature sensor, a flowmeter, a vibration sensor, a pH sensor, a tank level sensor, or a valve position sensor, for example.
  • the power control device may comprise a solid state relay, for example.
  • the wireless communication network may comprise a wireless mesh network.
  • embodiments described herein may be implemented in many different embodiments of software, firmware, and/or hardware.
  • the software and firmware code may be executed by a processor circuit or any other similar computing device.
  • the software code or specialized control hardware that may be used to implement embodiments is not limiting.
  • embodiments described herein may be implemented in computer software using any suitable computer software language type, using, for example, conventional or object-oriented techniques.
  • Such software may be stored on any type of suitable computer-readable medium or media, such as, for example, a magnetic or optical storage medium.
  • the operation and behavior of the embodiments may be described without specific reference to specific software code or specialized hardware components.
  • the processes associated with the present embodiments may be executed by programmable equipment, such as computers or computer systems.
  • Software that may cause programmable equipment to execute processes may be stored in any storage device, such as, for example, a computer system (nonvolatile) memory, RAM, ROM, Flash Memory, etc.
  • a single component may be replaced by multiple components and multiple components may be replaced by a single component to perform a given function or functions. Except where such substitution would not be operative, such substitution is within the intended scope of the embodiments.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Computer Networks & Wireless Communication (AREA)
  • Signal Processing (AREA)
  • Arrangements For Transmission Of Measured Signals (AREA)
  • Control Of Resistance Heating (AREA)
  • Remote Monitoring And Control Of Power-Distribution Networks (AREA)
US14/626,160 2015-02-19 2015-02-19 Wireless modules with power control circuits for heat trace system Active 2035-07-13 US9651184B2 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US14/626,160 US9651184B2 (en) 2015-02-19 2015-02-19 Wireless modules with power control circuits for heat trace system
EP16706275.1A EP3254531B1 (en) 2015-02-19 2016-01-20 Wireless modules with power control circuits for heat trace system
ES16706275.1T ES2686368T3 (es) 2015-02-19 2016-01-20 Módulos inalámbricos con circuitos de control de energía para sistema de rastreo de calor
CA2976904A CA2976904C (en) 2015-02-19 2016-01-20 Wireless modules with power control circuits for heat trace system
PCT/US2016/014152 WO2016133641A1 (en) 2015-02-19 2016-01-20 Wireless modules with power control circuits for heat trace system
CN201680018364.XA CN107407452B (zh) 2015-02-19 2016-01-20 热迹线系统、无线现场设备以及给热迹线电缆通电的方法

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Application Number Priority Date Filing Date Title
US14/626,160 US9651184B2 (en) 2015-02-19 2015-02-19 Wireless modules with power control circuits for heat trace system

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US20160245447A1 US20160245447A1 (en) 2016-08-25
US9651184B2 true US9651184B2 (en) 2017-05-16

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EP (1) EP3254531B1 (zh)
CN (1) CN107407452B (zh)
CA (1) CA2976904C (zh)
ES (1) ES2686368T3 (zh)
WO (1) WO2016133641A1 (zh)

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Publication number Priority date Publication date Assignee Title
US10278265B2 (en) * 2016-08-29 2019-04-30 Chromalox, Inc. Heat trace signal light
CN109996987B (zh) 2016-09-09 2021-06-18 恩文特服务有限责任公司 自动再熔化控制系统
EP3892060A1 (en) * 2018-12-07 2021-10-13 nVent Services GmbH Devices and method for electric heating trace system management
CN114585120A (zh) * 2020-12-01 2022-06-03 河北戈斯顿新能源科技有限公司 一种带有通断电功能的发热电缆
CN113757478A (zh) * 2021-08-02 2021-12-07 中国船舶电站设备有限公司 一种温控分布式船用管路防冻装置及其敷设方法
US20230367308A1 (en) * 2022-05-13 2023-11-16 Ciac Systems, Llc Electric heat trace power distribution and monitoring system for fault detection and predictive maintenance

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US4751495A (en) 1986-01-28 1988-06-14 Raychem Corporation Analog pulsed heat trace monitor or the like
US5475384A (en) 1992-06-26 1995-12-12 Nicotra Sistemi S.P.A. Remote addressable transducer provided with automatic calibration and digital compensation
US5900179A (en) 1996-01-16 1999-05-04 Intech 21, Inc. Heating cable control and monitoring method and system
US20090260438A1 (en) * 2008-04-22 2009-10-22 Hedtke Robert C Industrial process device utilizing piezoelectric transducer
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US4751495A (en) 1986-01-28 1988-06-14 Raychem Corporation Analog pulsed heat trace monitor or the like
US5475384A (en) 1992-06-26 1995-12-12 Nicotra Sistemi S.P.A. Remote addressable transducer provided with automatic calibration and digital compensation
US5900179A (en) 1996-01-16 1999-05-04 Intech 21, Inc. Heating cable control and monitoring method and system
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US20130154389A1 (en) * 2008-09-27 2013-06-20 Witricity Corporation Wireless energy transfer systems
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US20120054397A1 (en) * 2010-08-25 2012-03-01 Smartsynch, Inc. Interface bus for utility-grade network communication devices
DE102013206247A1 (de) 2013-04-09 2014-10-23 Winkler Gmbh Leitung und Heizeinrichtung für eine Leitung
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International Search Report and Written Opinion for PCT/US2016/014152, dated May 3, 2016 (12 pages).
U.S. Appl. No. 14/618,217, filed Feb. 10, 2015 (20 pages).
U.S. Appl. No. 61/865,851, filed Aug. 14, 2013 (17 pages).

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CN107407452B (zh) 2018-11-06
EP3254531A1 (en) 2017-12-13
CN107407452A8 (zh) 2018-01-12
CA2976904A1 (en) 2016-08-25
WO2016133641A1 (en) 2016-08-25
CN107407452A (zh) 2017-11-28
ES2686368T3 (es) 2018-10-17
CA2976904C (en) 2018-05-15
US20160245447A1 (en) 2016-08-25
EP3254531B1 (en) 2018-06-20

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